Structural reinforcements

ABSTRACT

The present invention is predicated upon the provision of systems and methods for reinforcement of a structural member. More particularly, the present invention is predicated upon unique carrier configurations and application of reinforcing material thereto. In one configuration, the application of reinforcing material is achieved without the use of fasteners, adhesives, or both, for placement, locating and restrictive movement of the reinforcing material onto the carrier.

CLAIM OF PRIORITY

This application claims the benefit of the filing date of U.S.Provisional Application No. 60/820,295, filed Jul. 25, 2006, thecontents of which are hereby entirely incorporated by reference.

FIELD OF THE INVENTION

The present invention is predicated upon the provision of a system andmethod for reinforcement of a structural member, which includesrestrictors for assisting in the placement, locating and restrictivemovement of activatable material on a carrier. In one particular aspect,the system and method is achieved without the use of fasteners,adhesives, or both, for placement, locating and restrictive movement ofthe activatable material on the carrier.

BACKGROUND OF THE INVENTION

For many years industry, and particularly the transportation industryhas been concerned with providing functional attributes sealing,baffling, acoustic attenuation, sound dampening and reinforcement toarticles of manufacture such as automotive vehicles. In turn, industryhas developed a wide variety of materials and parts for providing suchfunctional attributes. In the interest on continuing such innovation,the present invention seeks to provide an improved material and/orimproved part for providing such functional attributes. The materialand/or part can provide sealing, baffling, acoustic attenuation, sounddampening, combinations thereof or the like, but the part and/ormaterial have been found to be particularly adept at providingreinforcement.

SUMMARY OF THE INVENTION

The present invention provides improved systems and methods forreinforcement of a structural member. The present invention includesunique carrier configurations and activatable material placed thereoverfor providing structural reinforcement.

In a first aspect, the present invention provides a reinforcement systemfor a structural member. The system includes a carrier member having alength extending along an axis between a first end and a second end. Thecarrier member also includes one or more sidewalls joined together toform one or more cavities extending along the axis, which forms across-sectional shape roughly corresponding to the cross-sectional shapeof interior walls of a hollow structural member. The system alsoincludes an activatable material placed over the carrier. Theactivatable material is configured to expand upon application of heatand adhere to the interior walls of the hollow structural member toprovide reinforcement of the same. The system further includes one ormore restricting features located on or integrated with the carriermember. The one or more restricting features are configured to receivethe activatable material and limit movement of the activatable materialwith respect to the carrier.

In a second aspect, the present invention provides a reinforcementsystem for a structural member. The system includes a carrier memberhaving a length extending along an axis between a first end and a secondend. The carrier member includes one or more sidewalls joined togetherto form a plurality of cavities extending along the axis, which forms across-sectional shape roughly corresponding to the cross-sectional shapeof interior walls of a hollow structural member. The system alsoincludes an activatable material placed over the carrier. Theactivatable material is configured to expand upon application of heatand adhere to the interior walls of the hollow structural member toprovide reinforcement of the same. The system further includes one ormore caps located at the first, second or both ends of the carrier,wherein the one or more caps are configured to engage the end portion ofthe carrier.

In a third aspect, the present invention provides a reinforcement systemfor a structural member. The system includes a carrier member having alength extending along an axis between a first end and a second end. Thecarrier member also includes one or more sidewalls joined together toform a plurality of cavities extending along the axis and consecutivelyarranged along a height or width of the carrier, wherein the carriermember forms a cross-sectional shape roughly corresponding to thecross-sectional shape of interior walls of a hollow structural member.The system further includes a plurality of strips of activatablematerial placed over the carrier. The activatable strips are configuredto expand upon application of heat and adhere to the interior walls ofthe hollow structural member to provide reinforcement of the same. Thesystem further includes one or more restricting features integrallyformed with the carrier member to form a unitary structure. The one ormore restricting features are configured to receive the strips ofactivatable material and limit movement of the activatable material withrespect to the carrier. The system further includes one or more capslocated at the first, second or both ends of the carrier. The one ormore caps configured for engaging the end portion of the carrier andinclude one or more attachment features for attaching the carrier memberto the interior walls of the hollow structural member.

It should be appreciated that other features and aspects of theinvention exist including methods of forming the system, methods ofreinforcement of a structural member, or otherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an exemplary embodiment of a reinforcement systemaccording of the present invention.

FIG. 2 illustrates the system of FIG. 1 including exemplary end caps ofthe present invention.

FIGS. 3 and 4 illustrate perspective views of the end caps shown in FIG.2.

FIG. 5 illustrates another exemplary embodiment of a reinforcementsystem of the present invention.

FIG. 6 illustrates the system of FIG. 5 including exemplary end caps ofthe present invention.

FIG. 7 illustrates a perspective view of the end caps shown in FIG. 6.

FIG. 8 illustrates yet another exemplary embodiment of a reinforcementsystem of the present invention.

FIG. 8A-8D illustrates alternate configurations of the exemplaryembodiment shown in FIG. 8.

FIGS. 9A, 9B and 10 illustrate still additional exemplary embodiments ofthe reinforcement system of the present invention.

FIG. 11 illustrates a cross sectional view taken through an exemplaryembodiment of a reinforcement system of the present invention.

DETAILED DESCRIPTION

The present invention is predicated upon a system and method ofreinforcing a structural member, particularly an automotive frame orframe rail member. In doing so, the present invention contemplates acarrier, having an activatable material place thereover, which isconfigured for placement within a hollow structural member.Subsequently, the activatable material is activated causing the carrierto attach to the structural member and provide reinforcement thereto.

In one configuration, the activatable material is supported andmaintained on the carrier without the use of fasteners, adhesive bond,or both. With the present invention, the activatable material isrestrictively placed on or over the carrier which limits orsubstantially limits movement of the activatable material relative tothe carrier particularly during placement of the carrier into a cavityof a structural or otherwise. In doing so, the activatable material issecured with the carrier in the absence of a fastener.

Among the benefits achieved through this restrictive placement is thepotential for a reduction in manufacturing costs. Furthermore, thepresent invention also reduces required time to assemble thereinforcement system by reducing or eliminating the steps of utilizingattachment features for attaching the activatable material to thecarrier. Other benefits of the present invention will become apparent asshown and described herein.

In one aspect, by example referring to FIGS. 1 and 5, the presentinvention contemplates an improved reinforcement system 10, including acarrier member 12 configured for placement within a vehicle structuralmember, e.g. within a cavity of the structural member. The carrier mayinclude one or more cavities 16 extending the length of the carrier.Preferably, the carrier includes one or more applications of activatablematerial 18 placed thereover.

In another aspect, by example referring to FIGS. 2, 3, 4, 6, 7, and 10,the present invention further contemplates a feature 20 for locating thecarrier member 12 to the structural member 14. In one particularembodiment, this locating feature is configured to matingly engage withthe carrier member and includes one or more members (e.g. fasteners 22)for placement within apertures 23 or other corresponding recessesdefined in the structural member. In one particular embodiment, thelocating feature is further configured for attachment to an end portionof the carrier member and more particularly engages one or more cavitiesand/or opening 16 formed through the carrier. Optionally, the locatingfeature is shaped and/or sized for spacing the carrier away from thewalls of the structure being reinforced to allow passage of fluids suchas e-coat.

In yet another aspect, by example referring to FIGS. 1, 2, 5, 6 and 8through 11, the present invention also contemplates restrictivefeatures, such as restrictors 24, for quick and inexpensive placementand/or locating of the activatable material 18 onto carrier member 12,without the necessary use of fasteners. The carrier member, activatablematerial or both, may be formed with one or more of these features.Furthermore, other features, such as end caps 20, may also include oneor more of these restrictive features. Upon placement of the activatablematerial onto the carrier, movement of the material is limited andpreferably substantially limited by the restrictive features, withrespect to the carrier, prior to activation.

It should be appreciated that the above referenced examples are notlimiting as other examples and features of the present invention areshown and described herewith.

Carrier

As discussed above, the reinforcing system includes a carrier adaptedfor placement within a hollow cavity of a structural member. The carrieris preferably configured to extend along an axis and includes at least afirst end and a second end which reside on opposite ends of the axis.The carrier may also include one or more hollow cavities which extendalong the length or axis of the carrier. The carrier can be straight orcontoured along its length.

The carrier is formed of one or more walls that extend along the lengthof the carrier, which may be joined or otherwise integrated together.The carrier may have separate pieces that are separately made and thenassembled together, it may be integrally formed, or both. Optionally, itis contemplated that the one or more of the walls may be internal wallslocated substantially within exterior walls of the carrier. Preferably,upon joining of the walls, the carrier forms one or more (or aplurality) of cavities (e.g., 1, 2, 3, 4, 5, 6 or more cavities) thatextends along at least a portion of the length of the carrier and morepreferably the entire length. It is contemplated that the one or morecavities may form openings extending through the carrier between thefirst and second ends of the carrier, thereby allowing the passage offluids or other components through the carrier.

By example, referring to FIGS. 1 and 5, the carrier 12 may be formed ofa plurality of walls 26 which extend both internal and external to thecarrier and along the length thereof to form a plurality of cavities. Inthis configuration, the carrier includes a first cavity 16A, secondcavity 16B, third cavity 16C and fourth cavity 16D. Of course otherconfigurations are contemplated.

Referring to FIGS. 1 and 2, it is contemplated that one or more of thewalls 26 of the carrier 12 may be located adjacent an interior wall 30of the structural member 14 in which it is placed. Also, it iscontemplated that the cross-sectional profile of the carrier, as definedby the walls 26, or otherwise, may correspond to the cross-sectionalopening formed by the interior walls of the structural member.Accordingly, four or more walls may be located adjacent the interiorstructural members.

Optionally, the carrier may include one or more through holes 32 formedin the walls of the carrier. The through holes may provide reducedweight of the carrier. The through holes may also be used to directlycontrol any flow of the activatable material, or otherwise. Stillfurther, the through holes may be used to engage locating features 20for locating the carrier within the structural member.

The carrier may be formed of any of a variety of materials and can beformed of a single material or multiple materials. As examples, thecarrier may be formed of polymeric materials (e.g., thermoplastics suchas polyamide), metals (e.g., aluminum, steel, magnesium, metal alloys)combinations thereof or the like. As will be recognized, the techniquefor forming and shaping the carrier will typically depend upon thematerial of the carrier. Examples of techniques include, withoutlimitation, molding (e.g., injection, compression or blow molded),stamping, hydroforming, extruding or otherwise. Examples of suitablematerials and forming processes can be found in commonly owned U.S. Pat.No. 6,467,834, to Barz et al., the entire contents of which are hereinincorporated by reference for all purposes.

Activatable Material

The system 10 includes an activatable material 18 configured forproviding structural reinforcement properties upon activation and curingthereof. In one configuration, the carrier includes activatable materiallocated over the carrier. The activatable material may comprise anadhesive material, or otherwise includes adhesive qualities, for bondingto the carrier and structural member upon activation thereof.

Preferably, the activatable material is restrictively placed over thecarrier (via restrictor 24 or otherwise) such that movement of theactivatable material is limited or substantially limited with respect tothe carrier. In doing so, in some instances, the activatable material,the restrictors, or both, may be elastically or plastically deformablefor placement of the activatable material within one or more restrictivefeatures, between restrictive features or otherwise such that theconfiguration of the restrictive features and/or activatable materiallimits or substantially limits movement of the activatable material withrespect to the carrier.

The activatable material may be an expandable or foamable material thatis activated (e.g. by heat, moisture, radiation, chemical reaction orotherwise) to expand and then cure to form a strong bond betweenadjacent surfaces (e.g. attachment surfaces of the carrier andstructural member or otherwise). In one embodiment, the activatablematerial is formed of a high compressive strength heat activatedreinforcement material having foamable characteristics. In anotherembodiment, the activatable material may be particularly suited forvibrational dampening for stability to the structural member, reduceacoustic noise through the structural material or both. The material maybe generally dry to the touch or tacky and can be placed upon surfacesof members in any form of desired pattern, placement, or thickness, butis preferably a substantially uniform thickness. Though other heatactivated materials are possible for the activatable material, apreferred heat activated material is an expandable plastic, andpreferably one that is foamable. A particularly preferred material is anepoxy-based structural foam. For example, without limitation, thestructural foam may be an epoxy-based material, including an ethylenecopolymer or terpolymer that may possess an alpha-olefin.

Examples of suitable activatable materials can be found in commonlyowned U.S. Pat. Nos. 6,846,559, 6,941,719 and 6,921,130, herein entirelyincorporated for all purposes. In particular, one exemplary expandablematerial is L-5204 structural foam available through L&L Products, Inc.of Romeo, Mich. An example of a preferred structural foam formulationfor the adhesive material is an epoxy-based material that iscommercially available from L&L Products of Romeo, Mich., under thedesignations L5206, L5207, L5208, L5209, L-5220, L-7102, L-7220, XP321and XP721 or others.

The preferred materials can be processed by injection molding, extrusioncompression molding or with a mini-applicator, for example according tothe teaching of U.S. Pat. Nos. 7,048,019 and 5,358,397 herein entirelyincorporated by reference for all purposes. This enables the formationand creation of part designs that exceed the capability of most priorart materials. In one preferred embodiment, the activatable material (inits uncured state) generally is dry or relatively free of tack to thetouch. Moreover, the activatable materials may be applied to theattachment surfaces of the carrier members and/or connectors (e.g. endcaps or otherwise) before or after assembly of those componentstogether. In addition, as discussed previously, preformed patterns mayalso be employed such as those made by extruding a sheet (having a flator contoured surface) and then die cutting it according to apredetermined configuration in accordance with the chosen structure,panel or beam, and applying it thereto.

As previously mentioned, the activatable material may be a heatactivated, thermally expanding material. The material may becomereactive at higher processing temperatures, such as those encountered inan automobile assembly plant, when the material is processed along withthe automobile components at elevated temperatures or at higher appliedenergy levels, e.g., during painting preparation steps. Whiletemperatures encountered in an automobile assembly operation may be inthe range of about 148.89° C. to 204.44° C. (about 300° F. to 400° F.),body and paint shop applications are commonly about 93.33° C. (about200° F.) or slightly higher. If needed, blowing agent activators can beincorporated into the composition to cause expansion at differenttemperatures outside the above ranges.

Other exemplary activatable materials can include combinations of two ormore of the following: epoxy resin, polystyrene, styrenebutadiene-styrene (SBS) block copolymer, butadiene acrylo-nitrilerubber, amorphous silica, glass microspheres, azodicarbonamide, urea,dicyandiamide. See also, U.S. Pat. Nos. 6,649,243, 6,519,854, 6,387,470,6,546,693, 6,332,737, and 6,003,274. [SAC to provide these Sika patentnumbers. This should cover their acoustical foams and patentedcomposition just took out in the EPO opposition]

Placement of Activatable Material

The activatable material 18 is located adjacent to the exterior portionof the carrier 12, and may be in contact therewith or spaced therefrom.Preferably, the activatable material remains proximate to the carrierduring placement within the structural member 14 or otherwise. Theactivatable material, carrier or both may include a restrictive featurefor locating the activatable material proximate to the carrier.Preferably, the restrictive feature also limits or substantially limitsmovement of the activatable material with respect to the carrier.Optionally, as described herein, the activatable material may also beplaced on or with other components associated with the carrier, such asend caps, or otherwise.

In a first configuration, referring to FIGS. 1, 2, 5, 6 and 8 through11, the activatable material is restrictively located onto the carrierto limit or substantially limited movement of the material with respectto the carrier. Advantageously, placing and locating of the activatablematerial relative to the carrier may be performed without the use offasteners. In one preferred configuration, the restrictive placement ofthe activatable material is achieved through restrictors 24 placed orformed with the carrier, activatable material, or both.

The one or more restrictors 24 may be placed or formed upon one or morewall portions of the carrier. This may include opposing wall portions,four generally outwardly facing wall portions (for example, two oppositewalls generally perpendicular to two other opposite walls), orotherwise. Preferably, the restrictors are located on an exteriorportion of the carrier. More preferably, the restrictors are locatedadjacent the wall portions defining the structural member when thecarrier is placed therein. The restrictors may be located on 1, 2, 3, 4or more walls, including substantially all of the walls forming thecarrier or extending along the axis of the carrier.

Referring to FIGS. 1, 2, 5, 6, 9A, 9B and 10, examples of a firstrestrictor configuration is shown. In this configuration, the restrictorcomprises or includes a slotted portion 34 that extends along the lengthcarrier wall. The slotted portion includes a cross-sectional open areacomprising generally of a rectangle having a width and height. However,other shapes are contemplated including circular, elliptical, square,triangle, or otherwise. The cross-sectional open area may be generallyconsistent through the length of the carrier. The slotted portion mayalso include an opening or groove 36 which extends along the length ofthe carrier. The groove is located on an outer portion of the carrierfor receiving the activatable material or allowing the activatablematerial to exit the slotted portion during activation thereof.

As the slotted portion is configured for receiving the activatablematerial, the activatable material may have a cross-sectional shapecorresponding to the cross-sectional shape of the slotted portion. Theactivatable material may extend along substantially all or a portion ofthe slotted portion and may comprise a strip or other configuration. Inone configuration, the activatable material may be inserted into the endof the slotted portion. Alternatively, the activatable material may besnapped into the slotted portion, via the groove extending along theslotted portion. Either way, or otherwise, a friction fit may be createdbetween the slotted portion and the activatable material to prevent theactivatable material from exiting therefrom.

The carrier may include one or more stops 38 for preventing or limitingmovement of the activatable material within slotted portion. The stopsmay be integrally formed with the carrier or separately formed. In oneconfiguration, the stops comprise one or more pins or clips thatextending through an opening formed in the slotted portion of thecarrier. By extending into the slotted portion the pins or clips preventor limit movement of the activatable material along the slotted portion.

Referring to FIGS. 8 and 8A-8D, examples of a second restrictorconfiguration are shown. In this configuration, the restrictor comprisesor includes one or more features extending from the carrier, activatablematerial, or both, adapted to limit movement of the activatable materialin at least one direction. The restrictors may be separately formed andattached to the carrier or may be integrally formed with the carrier toform a unitary structure, as with all restrictor configurationsdescribed herein. As shown in drawings, the restrictors comprise one ormore, and preferably opposing members extending from the carrier, eachforming a cavity and/or opening for receiving the activatable materialand forming an end stop 40 for limiting movement of the activatablematerial parallel to the carrier axis, perpendicular to the carrieraxis, or both. For example, the stops may be configured to prevent thematerial from moving therepast, either prior to, during or afteractivation of the activatable material. Also, the stops may beconfigured to prevent movement along the axis of the carrier but allowmovement in a direction non-parallel to the carrier axis. Alternatively,the stops may be configured to allow parallel movement with respect tothe carrier axis but prevent non-parallel movement. The one or more endstops may include one or more tabs, protections, or otherwise, 42configured to prevent movement of the activatable material perpendicularto the axis of the carrier.

In a first example, referring to FIG. 8, the restrictors are formed of araised portion extending from one of the carrier walls. The restrictorincludes a top wall and sidewalls joining the top wall to the carrierwall, wherein each of the restrictors forms a cavity and includes anopening extending in the direction of an opposing restrictor. Thecavities and/or openings, as with each of the restrictors describedherein, may include a cross-sectional shape generally corresponding to aportion of the activatable material.

In a second example, referring to FIG. 8A, the restrictors may be formedof a turned up portion of the carrier wall that extends outwardly fromthe carrier wall and back towards an opposing restrictor to form atleast a portion of a cavity and opening extending towards the opposingrestrictor. The restrictors include sides wall tabs 42 extending fromthe carrier wall for limiting or preventing lateral movement of theactivatable material.

The restrictive features may include one or more intermediaterestrictors, e.g. tabs, projections, recess, opening, or otherwise, 44located between the restrictor end stops for preventing movementgenerally perpendicular to a line extending between the end stops. Forexample, in the example shown in FIG. 8, the intermediate stop includestwo generally adjacent tabs or stops having oppositely facing openings.The restrictors extend from the carrier wall and generally back towardsthe opposing intermediate restrictor. In this configuration, referringto FIG. 8C, the oppositely facing openings formed by the intermediaterestrictors allow a strip of activatable material 46 to be placedbetween the intermediate restrictors and rotated into the openingsthereby substantially preventing the strip of activatable material tomove away from the walls of the carrier. In another example, referringto FIG. 8B, the intermediate restrictor comprises one or more openingsformed through the carrier members for receiving a strip of activatablematerial and preventing perpendicular movement with respect to thecarrier axis. Upon placement into the openings, the strip of activatablematerial may be plastically and/or elastically deformed such that theend portions can be placed into openings formed by the end stoprestrictors, as shown in FIG. 8D.

Referring to FIG. 11, a third example of a restrictor configuration isshown. In this configuration, the restrictor comprises or includes oneor more engagement features 48 located with the reinforcement materialand configured to engage one or more corresponding engagement features50 located with the carrier. The engagement features may be integrallyformed or formed separate from the reinforcement material and carrier.In one configuration, the engagement features comprise a protrusionextending from the activatable material configured to engage an openingformed in the carrier. Optionally, one or more stops 38 may be furtherused to limit or substantially limit movement of the activatablematerial, carrier, or both, such that the engagement features do notdisengage.

In another configuration, referring to FIGS. 3 and 7, the activatablematerial may be placed over a portion of an end cap 20 which isconfigured for engagement with a carrier. The material may be locatedexternally or internally to the carrier upon attachment of the end capto the carrier. In one example, the end cap is configured with one ormore projections 52 adapted to fit within the cavities or openingsformed in the carrier. In this configuration, one or more of theprojections include activatable material located thereover. Uponactivation, the material adheres the end caps to the inner portion ofthe carrier. Optionally, the activatable material may also comprise, orotherwise include, an adhesive material configured for bonding to one ormore inner portions of the carrier, prior to, during or after activationof the activatable material. The adhesive may comprise a portion of theactivatable material or may be applied over the activatable material.

Attachment Features

Optionally, the carrier may include one or more locators for locatingthe carrier within structural member and maintaining the position of thecarrier. Such locators may be integrally formed with the carrier orcomprise a separate feature which engages the carrier and structuralmember. Suitable locators features include protrusions, extensions,tabs, springs, mechanical fasteners (e.g. threaded fasteners, hook andlatch, snap fittings, Christmas tree clips, or otherwise). Otherlocators include non-mechanical fasteners (e.g. friction fittings,adhesives, or otherwise).

The locators may be formed or placed about portions of the carrier.However, in one configuration at least one locator is at the first endof the carrier and at least one locator is at the second end. Thus it ispossible to generally orientate the axis of the carrier with the axis ofthe structural cavity.

End Caps

As previously mentioned, the system can include one or more end caps 20for placement at the first end, second end, or both ends, of thecarrier. The one or more end caps may be configured with one or morefeatures for improving reinforcement of the end cap, structural memberor both. Such improvement may comprise positioning of the carrier withinthe structural member prior to activation of the activatable material,controlling or preventing flow of the activatable material duringactivation, strengthening of the reinforcement system, structuralmember, or otherwise.

In one configuration, the end caps may be configured as a sound bafflefor inhibiting the transfer of sound, noise, vibration, or the like,along the structural member. In doing so, it is contemplated that theend caps may include an outer portion or walls having a correspondingshape to the interior wall of the structural member. The outer portionor wall of the end cap may substantially or entirely span the openingformed by the structural member in which the carrier and/or end cap isplaced in.

Additionally, the end caps may be configured to extend along at least aportion of an axis of the structural member cavity. The end caps mayinclude a length equal to at least about 2%, 5%, 10%, 25% or more of thelength of the carrier member. As should be appreciated, the combinationof the outer portion or walls and length, the end caps may comprise astand along reinforcement member in of itself. Accordingly, the end capsmay comprise a sound baffle member, reinforcement member or both such asbulkhead.

Optionally, the outer portion or walls of the end caps may includeactivatable material, as discussed herein, for attachment and/or sealingof the end cap to the structural member. The activatable material mayhelp to inhibit the transferring of sound, noise vibration or otherwise.Furthermore, the activatable material may further reinforce thestructural member. The Activatable material may extend along the outerportion or wall of the end cap, along an end portion of the cap, both,or otherwise.

For example, referring to FIGS. 2 through 4, 6, 7 and 10, three examplesof the end caps 20 of the present invention are shown. In theseexamples, the end caps may be configured to cover all or a portion ofthe openings formed through the carrier, which may control, limit orprevent all or a portion of the activatable material from entering orleaving the cavity of the carrier. The end caps may be placed at thefirst end, second end or both ends of the carrier.

The end caps may be configured for engagement with the interior surface,exterior surface or both surfaces of the carrier walls. It iscontemplated that the engagement of the end caps with the carrier maycomprise a friction fit. In one configuration, the friction fit maycomprise a friction fit formed between one or more projections 52 and/oractivatable material 18 and the interior walls forming a cavity of thecarrier. Of course, it is contemplated that the friction fit may beformed with an outwardly extending ring or lip 54 which extends about atleast a portion of the end caps and configured for forming a frictionfit with the exterior (or interior) walls of the carrier.

The engagement of the end cap may be further improved through the use ofan attachment feature for attaching the end caps to the carrier.Suitable attachment features include fiction fit, adhesives, fasteners,snap fittings, hook and latch, combinations thereof, or otherwise.Accordingly, it should be appreciated that the end caps and the carriermay include corresponding portions of an attachment feature. As anexample, referring to FIGS. 8, 10, and 12 the attachment feature maycomprise a snap fitting 56 configured for engaging a correspondingcomponent located on or with the carrier. For example, the snap fittingmay comprise one or more projections 58 extending away from the end cap.The projections may include a lip, latch, flange, or the like, 60 whichis configured to engage an opening, recess, groove, or the like, 62 ofthe carrier. In another example, the attachment feature may comprise afastener (such as a screw, clip, or otherwise) adapted to extend throughopenings formed in the carrier, end caps, or both, in order to attachthe same.

In one configuration, referring again to FIGS. 2 through 4, 6, 7 and 10,the end caps may be configured with one or more locators 64 for locatingthe end caps, and hence the carrier, with respect to an interior portionof the structural member. The locator may comprise a portion or the endcap or a separate component. In one configuration, referring to FIG. 10,the end cap included an integrally formed locator configured to engage acorresponding component of the structural member. Alternatively,referring to FIGS. 2 through 4, the locator may comprise a separatecomponent configured for engagement with both the end cap and thestructural member.

Preferably, the end caps and locators locate the carrier such that theamount of contact between the carrier, end cap, activatable material, orcombinations thereof and the structural member is minimized. This isdesirable as the structural members may be subjected to anti-corrosiontreatments (such as e-coating, or otherwise) for assisting in theprevention of corrosion. However, as previously mentioned . . . .

Suitable locators that may be used include fasteners such as clips (e.g.a ‘Christmas tree’ shaped clip), or the like.

In yet another example, referring again to FIGS. 2 through 4, 6, 7 and10, the end caps may also be configured for controlling the activatablematerial from entering or leaving the carrier cavity. In thisconfiguration, the end caps may cover all or a portion of the openingsformed through the carrier by the one or more cavities. In doing so, theend caps may include one or more openings 66 for allowing fluid (e.g.activating material, e-coating for the structural member, or otherwise)to flow therethough.

Advantageously, the end cap may include one or more reinforcementfeatures integrally formed, or attached thereto, for providingadditional support to the end caps, carrier, or both. Particularly, theadditional support may provide resistance to lateral forces with respectto the axis of the carrier, or otherwise. For example, referring toFIGS. 3 and 7, the reinforcement feature may comprise one or moreinternally formed ribs 68. In the configurations show, the ribs areformed within the projections extending from the end caps which areadapted for insertion and attachment to the carrier. Accordingly, it iscontemplated that the end caps may be configured to provide additionalreinforcement of the carrier by inserting one or more projections, ribs,or both, which are configured for attachment to an internal portion ofthe carrier, through adhesive and/or activatable material, such thatadditional support against lateral forces, or otherwise, is provided.Other reinforcement configurations are contemplated.

In another configuration, the end caps may be configured to limitmovement of the activatable material placed on the carrier. For example,referring to FIGS. 2 through 4, 6, 7 and 10, the end caps may include anoutwardly extending flange or lip 70 which extends to or beyond theouter circumference of the carrier walls. In doing so, restrictivelyplace material on the outer or interior portion of the carrier may beprevented from moving beyond the end cap and end portion of the carrier.

In still another configuration, it is contemplated that the end caps maybe alternatively attached directly to an end portion of a structuralmember (as oppose to the carrier), as described herein, to providereinforcement of the structural member, limit flow of any expandablematerial located within or external to the structural member, orotherwise.

The end caps may be formed of any suitable material including metal,plastic, rubber, ceramic, or otherwise. However, in one preferredconfiguration, the end caps are formed of a lightweight material such asa plastic and more preferable a thermoplastic or thermoset plastic. Thematerial of the end caps may be the same as the carrier or different. Itis contemplated, as described herein, that the end cap may be integrallyformed with the carrier through a molding process, such as blow molding,rotational molding or otherwise.

Applications

The reinforcing system of the present invention may be used in a varietyof applications which includes a structural member and which may benefitfrom reinforcement thereof. In one particular application, the systemmay be used in the vehicular industry for reinforcing structural systemsthereof to form a reinforced structural member. In doing so, any of thesystems herein can be placed in a structural member and activated toform the reinforced structural member.

For example, it is contemplated that the system may be used to reinforcevarious structural members of a vehicle including frame, frame rails,rockers, pillars, roof members, or otherwise. The structural member maycomprise one or more frame components (such as tubular frame members orotherwise) extending the length of a vehicle and/or other frame memberslocated therebetween (e.g. rocker frame members). In one particularlyadvantageous application, the system may be used to reinforce a framerail, rocker, or the like depending on the type of frame (e.g. unibody,etc.).

Unless stated otherwise, dimensions and geometries of the variousstructures depicted herein are not intended to be restrictive of theinvention, and other dimensions or geometries are possible. Pluralstructural components can be provided by a single integrated structure.Alternatively, a single integrated structure might be divided intoseparate plural components. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention.

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

1. A reinforcement system for a structural member, the systemcomprising: a carrier member having a length extending between a firstend and a second end, the carrier member including one or more sidewallsjoined together to form one or more cavities extending along the lengthof the carrier, the carrier including a cross-sectional shape roughlycorresponding to the cross-sectional shape of interior walls of a hollowstructural member; an activatable material placed over the carrier, theactivatable material is configured to expand upon application of heatand adhere to the interior walls of the hollow structural member toprovide reinforcement to the same; and one or more restricting featurelocated on or integrated with the carrier member, the one or morerestricting features being configured to receive the activatablematerial and limit movement of the activatable material with respect tothe carrier.
 2. The reinforcement system of claim 1, wherein the one ormore restricting feature includes two cavities located on opposite endsof the carrier member, the cavities forming openings extending towardseach other, the opening having a cross-sectional shape correspondingroughly to a portion of the activatable material prior to activation. 3.The reinforcement system of claim 2, wherein the cavities limit movementof the activatable material in a direction parallel to an axis of thecarrier and in a direction perpendicular to the axis.
 4. Thereinforcement system of claim 2, wherein the cavities are formed of araised portion of one of the carrier sidewalls and includes a top walland side walls integrally formed with the carrier to form a unitarystructure.
 5. The reinforcement system of claim 2, wherein each of thecavities are formed of a turned up portion that extending outwardly fromone of the carrier sidewalls and generally back towards each other, eachof the cavities further includes turned up side portions extendingoutwardly from said one of the carrier sidewalls, wherein the turned upportions are integrally formed with the carrier to form a unitarystructure.
 6. The reinforcement system of claim 2, wherein the one ormore restricting feature further include an intermediate retainingfeature located between the cavities formed on opposite ends of thecarrier member and integrally formed with the carrier member to form aunitary structure, the intermediate restricting feature comprising a tabextending generally outwardly and parallel to the carrier surface toform an opening for receiving the activatable material.
 7. Thereinforcement system of claim 6, wherein the one or more restrictingfeature includes two intermediate retaining features, the two retainingfeatures being axially displaced with respect to a carrier axis andfacing in opposite directions such that the openings formed by theintermediate retaining features extend generally towards each other. 8.The reinforcement system of claim 1, wherein the one or more restrictingfeatures include a slot extending along the length of the carriermember, the slot being formed with the carrier member to form a unitarystructure and includes an opening corresponding to a shape of at least aportion of the activatable material to limit movement of the activatablematerial in a direction perpendicular to a carrier axis.
 9. Thereinforcement system of claim 8, wherein the one or more restrictingfeature further includes one or more stops extending into the slot forlimiting movement of the activatable material in a direction parallel tothe carrier axis.
 10. The reinforcement system of claim 9, wherein thestop is formed by an end cap which matingly engages the end portion ofthe carrier member.
 11. The reinforcement system of claim 1, furthercomprising one or more end caps located at the first, second or bothends of the carrier, the one or more end caps configured for engagementthe end portion of the carrier.
 12. The reinforcement system of claim11, further comprising one or more attachment feature for attaching thecarrier member to the interior walls of the hollow structural member,the one or more attachment feature being located on or with the one ormore caps.
 13. The reinforcement system of claim 1, wherein the one ormore restricting feature includes one or more openings formed throughone of the one or more sidewalls that are shaped to slidably engage afinger formed on the activatable material.
 14. The reinforcement systemof claim 13, wherein the one or more restricting feature furtherincludes one or more stops limiting movement of the activatable memberafter engagement between the one or more openings and the finger.
 15. Areinforcement system for a structural member, the system comprising: acarrier member having a length extending along an axis between a firstend and a second end, the carrier member including one or more sidewallsjoined together to form a plurality of cavities extending along thelength of the carrier, the carrier including a cross-sectional shaperoughly corresponding to the cross-sectional shape of interior walls ofa hollow structural member; an activatable material placed over thecarrier, the activatable material is configured to expand uponapplication of heat and adhere to the interior walls of the hollowstructural member to provide reinforcement of the same; and one or morecaps located at the first, second or both ends of the carrier, the oneor more caps configured for engaging the end portion of the carrier. 16.The reinforcement system of claim 15, further comprising one or moreattachment feature for attaching the carrier member to the interiorwalls of the hollow structural member, the one or more attachmentfeatures being located on or with the one or more caps.
 17. Thereinforcement system of claim 16, wherein the plurality of cavities areconsecutively arranged along a height or width of the carrier.
 18. Thereinforcement system of claim 15, wherein the end cap comprises a soundbaffle.
 19. The reinforcement system of claim 15, wherein the end capcomprises a reinforcement member.
 20. A reinforcement system for astructural member, the system comprising: a carrier member having alength extending along an axis between a first end and a second end, thecarrier member including one or more sidewalls joined together to form aplurality of cavities extending along the axis and consecutivelyarranged along a height or width of the carrier, the carrier including across-sectional shape roughly corresponding to the cross-sectional shapeof interior walls of a hollow structural member; a plurality of stripsof activatable material placed over the carrier, the activatable stripsbeing configured to expand upon application of heat and adhere to theinterior walls of the hollow structural member to provide reinforcementof the same; one or more restricting features integrally formed with thecarrier member to form a unitary structure, the one or more restrictingfeatures being configured to received the strips of activatable materialand limit movement of the activatable material with respect to thecarrier; one or more caps located at the first, second or both ends ofthe carrier, the one or more caps configured for engaging the endportion of the carrier and forming a reinforcement member, sound bafflemember or both; and one or more attachment features for attaching thecarrier member to the interior walls of the hollow structural member,the one or more attachment features being located on or with the one ormore caps.